Bore and shaft assembly

ABSTRACT

An exemplary method includes positioning a plurality of seal rings on a shaft operably coupled to a turbine wheel and inserting the shaft into a bore via axial inward movement wherein during insertion, an outer seal ring contracts and then expands along a chamfer to reach an outer seal seat. Various other exemplary devices, systems, methods, etc., are also disclosed.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/884,232, entitled “Bore and Shaft Assembly”, filed on Jul. 3, 2004(now U.S. Pat. No. 7,066,719), which is incorporated by referenceherein. This application is related to U.S. patent application Ser. No.11/474,179, filed concurrently herewith (Jun. 23, 2006), which isincorporated by reference herein and which is a continuation applicationof aforementioned U.S. patent application Ser. No. 10/884,232 (now U.S.Pat. No. 7,066,719).

TECHNICAL FIELD

Subject matter disclosed herein relates generally to turbomachinery forinternal combustion engines and, in particular, seals for rotatingturbomachinery shafts.

BACKGROUND

Most turbines include a shaft that extends from a hub of a turbine wheelto a shaft bearing. For example, turbines for internal combustionengines typically include a turbine wheel housing that directs exhaustof an engine to a turbine wheel and another housing that houses abearing for a shaft coupled to the turbine wheel. In such anarrangement, the bearing exists in a lubricant environment thatlubricates the bearing to reduce frictional forces, dampen vibration,etc., to thereby allow for high speed operation of the turbine and theturbine wheel exists in an exhaust environment typically characterizedby high temperatures, high pressures and, depending on nature of theexhaust, corrosive reaction chemistry. To separate these twoenvironments, a variety of seal mechanisms have been proposed and used.

In general, such seal mechanisms aim to reduce flow of exhaust to thelubricant environment and/or flow of lubricant to the exhaustenvironment, both of which can be detrimental to performance (e.g.,efficiency, emissions, longevity, etc.). Flow of exhaust to thelubricant environment is usually referred to as “blowby” and flow oflubricant to the exhaust environment is usually referred to as“leakage”. Blowby typically occurs during high speed operation or loadwhere a significant positive pressure differential exists between theexhaust environment and the lubricant environment. Leakage typicallyoccurs during low turbine-power modes of operation, such as at engineidle, where the pressure differential is negative and/or minimal andinsufficient to overcome capillary or other lubricant transport forces.

As the turbomachinery industry trends toward increased turbine inletpressures, more stringent emission regulations, closed-crankcaseventilation systems, and increased customer sensitivity to the passageof exhaust gas through the turbine seal, a need for seal mechanisms thatreduce blowby and/or leakage will increase, and the design of suchmechanisms will become more challenging. Various exemplary sealmechanisms disclosed herein aim to reduce blowby and/or leakage.Further, various exemplary seal mechanism may allow for increasedperformance (e.g., efficiency, emissions, longevity, etc.), assemblyand/or disassembly of turbomachinery.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the various methods, devices, systems,arrangements, etc., described herein, and equivalents thereof, may behad by reference to the following detailed description when taken inconjunction with the accompanying drawings wherein:

FIG. 1 is a diagram of a conventional turbocharger and internalcombustion engine.

FIG. 2 is a cross-sectional view of an exemplary housing of aturbocharger.

FIG. 3 is a cross-section view of an exemplary seal mechanism for a boreand a shaft.

FIG. 4A is a top view of a step gap seal ring and FIG. 4B is a side viewof a section of the step gap seal ring.

DETAILED DESCRIPTION

Various exemplary methods, devices, systems, arrangements, etc.,disclosed herein address issues related to technology associated withturbochargers and are optionally suitable for use with electricallyassisted turbochargers.

Turbochargers are frequently utilized to increase the output of aninternal combustion engine. Referring to FIG. 1, a prior art system 100,including an internal combustion engine 110 and a turbocharger 120 isshown. The internal combustion engine 110 includes an engine block 118housing one or more combustion chambers that operatively drive a shaft112. As shown in FIG. 1, an intake port 114 provides a flow path for airto the engine block 118 while an exhaust port 116 provides a flow pathfor exhaust from the engine block 118.

The turbocharger 120 acts to extract energy from the exhaust and toprovide energy to intake air, which may be combined with fuel to formcombustion gas. As shown in FIG. 1, the turbocharger 120 includes an airinlet 134, a shaft 122, a compressor 124, a turbine 126, a centerhousing or assembly 128 and an exhaust outlet 136.

The output of the compressor 124 flows to a heat exchanger (e.g.,cooler) 130 that is typically used to extract heat from the compressedintake air prior to the intake port 114 of the engine 110. As mentionedin the Background section, compression causes friction between airmolecules and hence frictional heating. Thus, air at a compressor outletgenerally has a considerably higher temperature than air at a compressorinlet. In FIG. 1, the heat exchanger 130 is typically an intercoolerthat acts to remove heat from compressed air before the compressed airreaches one or more combustion chambers of the engine 110.

Referring to the turbine 126, such a turbine optionally includes avariable geometry unit and a variable geometry controller. The variablegeometry unit and variable geometry controller optionally includefeatures such as those associated with commercially available variablegeometry turbochargers (VGTs), such as, but not limited to, the GARRETT®VNT™ and AVNT™ turbochargers, which use multiple adjustable vanes tocontrol the flow of exhaust across a turbine. Of course, an exemplaryturbocharger may employ wastegate technology as an alternative or inaddition to variable geometry technology.

FIG. 2 shows a cross-section of an exemplary housing 228 for housing abearing to support a turbine wheel shaft. The exemplary housing 228 isoptionally suitable for use as the housing 128 of FIG. 1. The exemplaryhousing 228 includes a through bore 242 that includes a compressor boreend or segment 244 and a turbine bore end or segment 248. In general,such a through bore has a longitudinal axis that is coaxial with theaxis of rotation of a turbine wheel and a compressor wheel. A dashed boxindicates an exemplary seal mechanism 300 of the turbine bore segment248 of the bore 242 that is shown in more detail in FIG. 3 along withadditional components.

FIG. 3 shows a cross-section of the exemplary seal mechanism 300 of theturbine bore segment 248 along with seal rings 254, 258 and a shaft 280.In this example, the exemplary seal mechanism 300 includes the sealrings 254, 258, an inner surface of the turbine bore segment 248 (e.g.,proximate to a turbine wheel), and an outer surface of the shaft 280that act together to create resistance to flow. The seal mechanism 300creates resistance via a tortuous path and reduced flow area, sometimesreferred to as a labyrinth seal. In addition, upon seating, wear,heating, etc., of various components of the seal mechanism 300,tortuosity or other properties of the path may change.

The surface of the turbine bore segment 248 includes an outer seat thathas a radial depth Δr_(So) as measured from an inner side step of theouter seat. The inner surface of the turbine bore segment 248 alsoincludes an inner seat that has a radial depth Δr_(Si) as measured froman inner side step of the inner seat. The outer seat receives the outerring 258 while the inner seat receives the inner ring 254. The outerring 258 includes an axial width X_(o), which is less than the axialwidth of the outer seat and the inner ring 254 includes an axial widthX_(i), which is less than the axial width of the inner seat. Thus, somemovement or axial expansion may occur for the rings in their respectiveseats wherein the inner steps of the seats generally limit inwardmovement of the rings 254, 258.

In the exemplary bore segment 248, the outer seat includes a groove ofaxial width X_(Go) and the inner seat includes a groove of axial widthX_(Gi). In general, the axial width of a groove is less than the axialwidth of a respective ring. In this example, each groove coincides atone axial end with a respective inner side step, which may limit inwardaxial movement or expansion of a ring.

The exemplary shaft 280 includes an outer slot that substantiallycoincides with the outer ring 258 and an inner slot that substantiallycoincides with the inner ring 254. In general, the axial width of a slotexceeds the axial width of a respective ring.

For purposes of explanation, various pressures P₁, P₂ and P₃ are shownwherein P₁ represents an exhaust environment pressure, P₂ represents anintermediate pressure and P₃ represents a lubricant environmentpressure. Where P₁ exceeds P₃, exhaust flow in the direction of P₁ to P₃may be expected (e.g., from exhaust environment to lubricantenvironment) wherein P₁>P₂>P₃. Where P₃ exceeds P₁ or where thedifference between P₃ and P₁ is insubstantial (e.g., a few centimetersof water), then lubricant may flow in the direction of P₃ to P₁. Again,lubricant flow may occur due to capillary and/or other lubricanttransport forces (e.g., gravity, etc.). While exhaust flow is typicallya more serious concern during turbine operation, the seal mechanism 300may also act to resist lubricant flow.

As shown in FIG. 3, the inner ring 254 and the outer ring 258 act tocreate resistances in series, for example, according to the followingequation (Eqn. 1):R _(Total) =R _(inner) +R _(outer)+α  (1)where the term α represents other resistances. Depending on values ofvarious parameters, R_(inner) may differ from R_(outer) and, as alreadymentioned, such values may change during operation.

While the rings 254, 258 of the exemplary mechanism 300 act to increaseresistance to flow, for example, compared to a single ring mechanism,the exemplary seal mechanism 300 also includes features that facilitateassembly and/or disassembly of the shaft 280 from the bore 248. Aparticular feature that facilitates assembly and/or disassembly is achamfer in the wall of the bore 248, defined in this example by an axialchamfer rise distance X_(Cr) and a chamfer rise angle γ_(Cr) whichtogether may determine a radial chamfer distance Δr_(C). A value for anexemplary chamfer rise angle γ_(Cr) is optionally between approximately30° and approximately 50°. While the exemplary chamfer has asubstantially linear cross-section, other examples may include chamferswith non-linear cross-section, optionally in combination with linearcross-section. For example, a chamfer may include a curvedcross-section.

The distance from the step of the outer seat to the chamfer isoptionally selected in combination with an outer ring axial width toallow for adequate excursion of the outer ring in the outer seat duringuse or operation without having the outer ring reach the chamfer. Ofcourse, the chamfer will offer some resistance to movement of the outerring toward the turbine end of the bore, which may vary depending onchamfer rise angle, chamfer rise distance, chamfer cross-section, etc.;however, such resistance may typically be overcome during assemblyand/or disassembly.

During assembly of the seal mechanism 300, insertion of the outer ring258 may occur from the turbine side opening of the bore 248 wherein asthe outer ring 258 traverses axially away from the turbine side openingit reaches the chamfer. The chamfer allows the ring 258 to expandradially (e.g., by the radial distance Δr_(C)) as the outer edge surfaceof the ring 258 contacts the outer seat.

Of course, in an alternative assembly technique, the ring 258 could becompressed or contracted to a dimension smaller than the smallestchamfer radius (or diameter) and then expand by an amount greater thanthe radial distance Δr_(C) to meet the inner wall of the bore 248.However, rings typically have a limited range of contraction andexpansion and thus according to various examples discussed herein, achamfer with a small radial distance is often preferred.

During disassembly, radial contraction of the outer ring 258 may occuras the ring 258 traverses axially across the chamfer. Thus, according tothe exemplary seal mechanism 300, the ring 258 is typically capable ofradial expansion and radial contraction to thereby cooperate with thechamfer and allow for ease of assembly and/or disassembly of the shaft280 from the bore 248.

The exemplary bore 248 also includes a chamfer plateau having an axialwidth X_(C) followed by a second chamfer or conical section ofincreasing radius. The second chamfer is disposed at an angle γ_(Cd),which may differ from the chamfer rise angle γ_(Cr). The second chamferallows for radial expansion or radial contraction of the outer ring 258upon assembly and/or disassembly.

In the exemplary seal mechanism 300, the chamfer adjacent the outer seatfor the outer ring does not interfere with insertion of one or moreinner seal rings in the bore segment 248. In the example of FIG. 3, thechamfer plateau and the inner seat have substantially equivalent radii.Thus, the inner ring 254 may traverse the chamfer plateau to be seatedin the inner seat. In general, the rings 254, 258 are positioned uponassembly in a manner whereby a clearance exists between a respectivering and an inner step. During use or operation, the clearance maydecrease, a ring may contact the inner step and/or the clearance mayincrease.

With respect to the shaft 280, the exemplary mechanism 300 requires ashaft with two ring slots. In general, the slots are cut in the turbinewheel hub sufficiently inboard of the weld joint to avoid a heataffected zone. In the exemplary mechanism 300, the slots are ofdifferent axial widths: a narrower width outer slot and a wider widthinner slot. The slots are dimensioned to result in desired sideclearances when fitted with their respective seal rings. In variousexamples, the inner ring is sufficiently wide to prevent installationinto the outer slot, which could complicate assembly (i.e., allow formisplacement of the inner ring, etc.). An exemplary relationship betweenan inner ring axial width X_(i) and an outer ring axial width X_(o) isoptionally on the order of approximately 1.2 (e.g., where the inner ringaxial width is approximately 20% wider than the outer ring axial width).

As described above, the turbine bore segment 248 includes twosubstantially perpendicular steps that extend radially inward and areadjacent respective seal ring seats. The inner step is optionallymachined in the manner of a conventional single-ring seal mechanism. Theouter step surface optionally results from machining of a recessedsecondary seal bore or outer seat diameter wherein the difference indiameters between the primary bore or inner seat and secondary bore orouter seat provides a necessary step without intruding into the primarybore or inner seat diameter. In various examples, the outer edge of therecessed secondary bore or outer seat is configured as a chamfer of asmall enough angle to allow removal of the outer ring.

The axial width of the recess of the outer seat, including the chamfer,is optionally selected to be approximately 80% of the axial width of theinner ring. Such dimensions allow the inner ring to bridge and axiallytraverse the outer seat and chamfer upon installation of the inner ringwherein a portion of the inner ring retained in the bore outboard of theinner seat and chamfer recess maintains the inner ring at the inner sealbore or inner seat diameter. The axial width of the outer seat orrecessed bore, from the inner end of the chamfer to the step of theouter seat, is optionally sized to allow a narrow outer ring to relaxand expand out to the outer bore or outer seat diameter. In such anexample, the outer seat diameter typically exceeds an inner seatdiameter. An exemplary a radial depth Δr_(So) as measured from an innerside step of the outer seat is optionally on the order of a tenth toseveral tenths of a millimeter (e.g., approximately 0.1 mm toapproximately 0.3 mm).

The expansion of the outer seal ring to the outer seal bore diameter(e.g., seat diameter) has the effect of increasing the installed end gapof the ring. As this gap affects the flow area through and around thering, it is often desirable to maintain this gap at a minimum typicallydictated by necessity to allow for installation and thermal expansionduring operation. To compensate for any detrimental effect such anexample may have on seal performance, a step gap geometry may beemployed in the outer seal ring to increase flow resistance.

As already mentioned, the chamfer can facilitate disassembly of theexemplary seal mechanism. For example, the chamfered outer edge of theouter seat may serve to compress the outer ring as the shaft iswithdrawn from the bore.

According to various exemplary mechanisms, during use or operation, aseal ring will typically wear-in under gas loading such that an edge ofthe ring contacts a step in its seat wherein such contact can serve tolimit further wear of a ring.

As discussed with respect to the exemplary mechanism 300, an exemplarybore for a shaft of a turbomachine may include a longitudinal axisextending generally from an inner end to an outer end of the bore, anouter seat disposed proximate to the outer end of the bore at an outerseat radius (r_(o)) for an outer seal ring wherein the outer seatincludes an inner end, an outer end, a step at the inner end extendingradially inward to a step radius (r_(s)), and a chamfer at the outer endextending radially inward over an outward axial distance to a chamferplateau radius (r_(cp)) and an inner seat disposed inward the outer seatat an inner seat radius (r_(i)) for an inner seal ring wherein the outerseat radius (r_(o)) exceeds the inner seat radius (r_(i)).

As discussed, the inner seat may include an axial width and the outerseat may include an axial width wherein the axial width of the innerseat exceeds the axial width of the outer seat. The inner seatoptionally includes a groove adjacent the step of the inner seat and theouter seat optionally includes a groove adjacent the step of the outerseat. A chamfer plateau may be included or refer to a minimum radius ofa chamfer. Such a chamfer plateau optionally includes a radiusapproximately the same as an inner seat radius (r_(i)). In general, anexemplary bore increases in radius axially outward from a chamferplateau.

As shown in FIG. 3, the outer seal ring 258 is disposed between the stepof the outer seat and the chamfer and the inner seal ring 254 isdisposed between the step of the inner seat and the step of the outerseat wherein the axial width of the inner seal ring optionally exceedsthe axial width from the step of the outer seat to the plateau of thechamfer. In various examples, the axial width of the inner seal ring 254exceeds the axial width of the outer seal ring 258.

The exemplary bore segment 248 is shown as including a plurality of sealrings and a shaft operably coupled to a turbine wheel wherein the bore,the seal rings and the shaft form a labyrinth seal. An exemplary methodincludes positioning a plurality of seal rings on a shaft operablycoupled to a turbine wheel (e.g., optionally connected, part of theturbine wheel, etc.) and inserting the shaft into a bore via axialinward movement wherein during insertion, an outer seal ring contractsand then expands along a chamfer to reach an outer seal seat. In thisexemplary method, during the insertion, an inner seal ring optionallybridges a seat for an outer seal wherein the seat is disposed between astep and a chamfer. Another exemplary method includes extracting ashaft, operably coupled to a turbine wheel (e.g., optionally connected,etc.), from a bore via outward axial movement wherein the shaft includesa plurality of seal rings and wherein during the extraction, an outerseal ring contracts along a chamfer to reach a chamfer plateau andwherein an inner seal ring bridges a seat for the outer seal ring thatis disposed between a step of the seat and the chamfer plateau.

As already mentioned, a ring may employ a step gap geometry. FIG. 4Ashows a top view of an exemplary ring 450 that includes a step gap 452and FIG. 4B shows a side view of a section of the exemplary ring 450that includes the step gap 452. The exemplary ring 450 is optionallysuitable for use as an inner ring, an outer ring and/or an intermediatering in an exemplary seal mechanism. For example, the ring 450 may beused in the exemplary seal mechanism 300 as the inner ring 254 and/orthe outer ring 258. In particular, consider use of the ring 450 as theouter ring 258. In such an example, the step gap 452 allows for radialcontraction of the ring to a dimension sufficient to traverse thesmallest radius of the chamfer. As the step gap ring traverses thechamfer, the step gap 452 may expand to thereby allow expansion of thering and seating of the ring in the outer seat.

While a particular step gap is shown in FIG. 4B, other mechanisms thatallow for contraction and expansion of a seal ring may also be suitablefor use in an exemplary seal mechanism.

Various exemplary seal mechanisms disclosed herein include a chamferthat allows for assembly and/or disassembly of one or more seal rings.This feature allows for ease of checking wear of an outer ring and/orone or more inner rings.

Various exemplary mechanisms optionally include more than one chamferwherein, for example, each chamfer corresponds to a seal ring and isadjacent a seal ring seat. In one example, an outer chamfer correspondsto an outer ring seat, an intermediate chamfer corresponds to anintermediate ring seat and an inner ring optionally has an axial widthselected to bridge an outer seat and an intermediate seat and a minimumdiameter approximately equal to or less than the minimum diameter (e.g.,chamfer plateau) of the intermediate chamfer to thereby allow the innerring to be positioned in an inner ring seat.

Various exemplary mechanisms include seal rings of differentcross-section. For example, an inner ring may include a sufficientlywider axial dimension than an outer ring thereby allowing it to ‘bridge’an undercut bore section or seat for an outer ring. In this manner, theinner ring is able to bypass the inner step of the outer seat duringinstallation, allowing the inner ring to reside in its own seat, whichis optionally a conventional seal ring seat.

Various exemplary mechanisms include a chamfer or angled edge risingfrom an outer seat that optionally acts as part of the outer seat toretain a seal ring during use or operation. The chamfer provides forcontraction of the outer ring during disassembly and/or allows forexpansion of the outer ring during assembly.

Various exemplary multiple seal ring mechanisms offer improved sealdurability (seal ring wear) compared with conventional single-ringmechanisms. An exemplary mechanism includes a wear-limiting step forboth an inner ring and an outer ring. While various examples pertain toa turbine end or segment of a bore, such exemplary mechanisms may besuitable for compressor end or segment of a bore to reduce intake airflow to a center housing and/or leakage of lubricant to a compressorhousing.

Although some exemplary methods, devices, systems arrangements, etc.,have been illustrated in the accompanying Drawings and described in theforegoing Detailed Description, it will be understood that the exemplaryembodiments disclosed are not limiting, but are capable of numerousrearrangements, modifications and substitutions without departing fromthe spirit set forth and defined by the following claims.

1. A method comprising: positioning a plurality of seal rings on a shaftoperably coupled to a turbine wheel; and inserting the shaft into a borevia axial inward movement wherein during insertion, an outer seal ringcontracts and then expands along a chamfer to reach an outer seal seat.2. The method of claim 1 wherein during the insertion, an inner sealring bridges a seat for an outer seal wherein the seat is disposedbetween a step and a chamfer.
 3. The method of claim 1 wherein duringthe insertion, an inner seal ring bridges the outer seal seat.
 4. Themethod of claim 1 wherein the outer seal seat is disposed between a stepand a chamfer.
 5. The method of claim 1 wherein the positioningcomprises positioning an inner seal ring and an outer seal ring on theshaft.
 6. The method of claim 1 wherein the positioning comprisespositioning an inner seal ring in an inner slot of the shaft.
 7. Themethod of claim 1 wherein the positioning comprises positioning theouter seal ring in an outer slot of the shaft.
 8. The method of claim 1wherein the positioning comprises positioning the outer seal ring in anouter slot of the shaft and an inner seal ring in an inner seal ring ofthe shaft wherein the axial width of the outer slot and the axial widthof the inner slot differ.
 9. The method of claim 8 wherein the axialwidth of the inner slot exceeds the axial width of the outer slot. 10.The method of claim 1 wherein each of the plurality of seal ringscomprises a mechanism that allows for contraction and expansion.
 11. Themethod of claim 8 wherein at least one of the seal rings comprises astep gap mechanism that allows for contraction and expansion.
 12. Themethod of claim 1 wherein the bore comprises a bore of a center housing.13. A turbocharger assembly assembled by a process, the processcomprising: positioning a plurality of seal rings on a shaft operablycoupled to a turbine wheel or a compressor wheel; and inserting theshaft into a bore via axial inward movement wherein during insertion, anouter seal ring contracts and then expands along a chamfer to reach anouter seal seat.
 14. The turbocharger assembly assembled by the processof claim 13 wherein the bore comprises a bore of a center housing. 15.The turbocharger assembly assembled by the process of claim 13 whereinthe positioning comprises positioning the plurality of seal rings on ashaft operably coupled to a turbine wheel.
 16. The turbocharger assemblyassembled by the process of claim 13 wherein the positioning comprisespositioning the plurality of seal rings on a shaft operably coupled to acompressor wheel.
 17. A method comprising: extracting a shaft, operablycoupled to a turbine wheel, from a bore via outward axial movementwherein the shaft includes a plurality of seal rings and wherein duringthe extraction, an outer seal ring contracts along a chamfer to reach achamfer plateau and wherein an inner seal ring bridges a seat for theouter seal ring that is disposed between a step of the seat and thechamfer plateau.
 18. The method of claim 17 further comprising checkingat least one of the seal rings for wear.
 19. The method of claim 17further comprising inserting the shaft into the bore via axial inwardmovement wherein during insertion, the outer seal ring contracts andthen expands along the chamfer to reach the seat for the outer sealring.
 20. The method of claim 17 further comprising inserting the shaftinto the bore via axial inward movement wherein during insertion, theinner seal ring bridges the seat for the outer seal ring.